Our original idea began with a simple premise: can we create a more efficient zipper? We decided to take our idea to other members of our class. After consulting with the other classmates, we determined that the ability for the zipper to become jammed was the primary problem, while actually connecting the two sides of the zipper was a close second. After tossing around ideas, the idea of an electromagnet intrigued us. The idea of being able to completely scrap the whole idea of a zipper and just make two rods where the zippers had once been seemed like a viable option. After initial experimentation with small electromagnets, where we were able to wrap copper wire around a metal screw and magnetize it with a standard 9-volt battery, the idea stuck with us.
Our original prototype involved two rods where the zippers on a jacket would be. One side would have the ability to be magnetically attracted, but not being itself magnetic, while the other side would be a charged material with a button or switch to turn on the charge. With one side charged, the other side would be magnetically attracted, and the two sides would automatically come together, completely removing the ability for the zipper to be jammed, or for starting the attraction process. Soon after experimentation, we found that the charged rod heated up too much, and it was difficult to control what it attracted, so we went back to the drawing board.
We began thinking about the qualities of zippers that we wanted to mimic. Our “zipper” had to be flexible. By cutting a bike chain and attaching ferrous, neodymium magnets in between the links, we were able to make a semi-flexible prototype. After seeing the effectiveness of the magnets, we decided to shy away from electromagnets and began experimenting with 5mm magnetic cubes. We developed a 3D printed prototype in which the magnets were placed into slots in two polymer rods across from one another and attracted its twin opposite it, which allowed us to create an effect that once the first links were established, the rest would follow suit and connect to their twins. Once polyolefin heat shrink tubing wrap was placed around it for stability and waterproofing, the magnetic zipper prototype was complete.
The next step for this project was to physically attach the M-zip to an article of clothing to see what the M-zip looks like when finished, and to test its operation. A machine-sewn model would allow for more stability, and a cleaner look when finished, but we only had time to use glue and a little hand sewing. We attached it to a nylon jacket and found that it worked well, but was slightly bulky. A potential improvement would be to reduce the bulk of the zipper itself to lessen the weight and bulky look.